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2003 Roadstar 1600

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  • #61
    Well shoot, the time has gone by fast!
    Me and some friends are heading out from san diego to yosemite in 3 days
    The bike still isn't done.....
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    But I have got a lot done I guess
    I got a few more layers of clear coat on the tank, rear fender, side covers, tank, and fairing
    I will be wet sanding it one last time then a final clear coat layer
    I also got a new front tire for the trip and checked all the regular maintenance stuff

    As you can see I managed to modify the pipes I had on there, I found a 2 into 1 exhaust tip at the swap meet along with a fishtail tip muffler
    I shortened the muffler and removed the baffle, I can feel a substantial difference in power especially in mid range, it lowered the sound down a little too which is useful around cops but it still has a mean grown when accelerating and on decel.
    Here you can see the original length then after it was shortened

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    the 2 into 1 isnt the best looking but it works for $2 and I got some welding practice out of it too, that thin stuff isn't so bad now

    I wrapped it in some cheap "titanium" wrap I got on ebay, I got the 2" on accident, I should have got the 1" for tighter wrapping but you live and you learn
    If you decide to wrap your exhaust make sure you soak it first!

    I also got around to working on my seat cover, I got a singer fashion mate from walmart for $150, it was barely able to handle the thin marine I was using but it worked I guess
    I went with a diamond stitch and horizontal pleat pattern
    I covered the entire seat in duct tape, then used a sharpie to mark out the seams, I made a top piece which got the pleats, then several side covers

    To get the pattern on top I cut out the vinyl quite a bit bigger than it needed to be, then I cut out a piece of 1/2" foam the same size, as well as another piece of fabric to go under the foam, i cant recall the name of it but i know it is the same material pillow cases are made of, it's there to secure the foam to the vinyl when sewing a pattern
    I sewed a long strip of vinyl to the tube edging, then started lining things up and sewing them together
    Click image for larger version

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    Overall, it came out somewhat crappy, when i made the templates they might have been a bit off, or maybe it was just because I don't really know what I'm doing, but either way the back rest came out crooked, the top pleats where almost flat since I had to stretch the side pieces around to get rid of wrinkles, all sorts of mess that i didn't think of, but you can be sure I'll remember it next time i make a seat!

    It looks decent, but I know I can make one better, I'll have to upload pictures of it later since it isn't on the bike at the moment, at least it's comfy, this trip is around 1700 miles and I needed a good saddle!

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    • #62
      I am currently hooking up all the wiring for my dash
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      It's got a few more buttons and has been painted but It's currently on the floor waiting for me to figure out where the damn tach wire goes......
      I had this exact problem when i first tried to figure it out, and now I can only remember saying "AAAHAAAA!!!! IT WAS SO OBVIOUS WHERE THIS WIRE GOES!"
      And now I can't remember where it went to save my life.....

      I also got a cheap cat face brake light from ebay, I was going to replace my cracked lens dietz one on the fender but i threw it on the license plate mount and it looks cool there so I guess I'm keeping both

      Click image for larger version

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      Found my shifter knob a hat at the thrift store!


      Click image for larger version

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      I actually sought out some tiny sunglasses which I'll put on when I get to Born free, I just have to try and metal flake them first


      Being as last minute as I can I am trying to get my marshall oil gauge hooked up before the trip, Hopefully I can find the fittings I need in town

      We leave wednesday and I haven't got a single thing packed, instead I decided to check my build thread in hopes that I posted where that stinkin tach wire went somewhere on here but no luck of course, then I decided to update the thread....



      Comment


      • #63
        awesome and creative build.

        your Flying Eyeball at your Sissybar is awesome, also the Hamdshifter and generell Paintjob. yim also considering to build myself an 2 in 1 Fishtail exhaust.

        I think an 21 Wheel would kill your look.

        Comment


        • #64
          Originally posted by El_Mipo View Post
          awesome and creative build.

          your Flying Eyeball at your Sissybar is awesome, also the Hamdshifter and generell Paintjob. yim also considering to build myself an 2 in 1 Fishtail exhaust.

          I think an 21 Wheel would kill your look.
          Thanks!
          At this point I agree that a 21 wouldn't look right, i plan on swapping out the front end with a sportster one with extended fork tubes and I think a 19" would fit better

          Comment


          • #65
            So I decided to knock out the clear coat the other day, there must have been too much humidity in the air because the clear began to wrinkle about an hour after spraying it ( my current paint booth is some trash cans out front under a tree that loves to throw leaves)
            Basically the paint on the tank was ruined, the rest of the parts came out good
            As the last bit of sanity left me I began to pick at the clear coat, 2 days before I leave on a trip to yosemite and I went and pulled the ol "shoulda left it alone"
            I picked until most of the clear I sprayed was gone, it hadn't fully cured so it was still somewhat rubbery
            I ended up wet sanding the now ruined design on the tank until it was gone, somehow the wrinkling hadn't got to the metal flake layer!

            I sanded and sanded, then sanded more, sanded until my fingers where sore!
            I dusted off the airbrush and went to work, i ended up getting a design on there in a few hours, then sealed it with some clear coat (the weather was much better today)

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            As you can see my trash can is slowly being flaked

            I managed to get everything back on the bike including a new universal speedo/ tach
            I haven't got a chance to test it yet but hopefully it works
            Me and some buddies leave for yosemite at midnight tonight, I still can't believe I was painting the tank the day of our trip

            Comment


            • #66
              Well that's a bitch. But it looks good. Hope the trip goes smoothly. Post some photos and updates from the road if you can.

              Comment


              • #67
                The trip didn't go as planned and these last few weeks have been rough
                One of my best friends lost control of his bike on our first day of the trip, he went down on the freeway and passed away.
                We cancelled the trip and headed back to san diego the next day
                I've never had someone this close to me pass away so suddenly, it has been an emotional roller coaster but through the situation God has been giving me, his friends, and family, comfort through the difficult times.
                Any prayer for his friends and family is greatly appreciated

                As far as riding again, the pastor we talked to the day it happened shared this verse 2 Timothy 1:7
                For God has not given us a spirit of fear, but of power and of love and of a sound mind.


                I have rode since it happened, I don't believe God used this situation to scare us away from riding, but for me it is a reminder that no one is promised tomorrow and that although I may not fully understand why this has happened at the moment, I know it is because of God's timing and will.



                As for the road star, I've fiddled with a few things on it, trying to keep myself busy, nothing major.
                I managed to figure out the wiring for the speedometer, or at least the tachometer portion of it
                The black and yellow tach wire went to the wire that comes off of the ignition pickups
                the diagram says to connect it to the positive lead on the ignition coil itself, for some reason this doesn't work, I traced the wire from the ignition coil back down to the pickup sensor 2 pin connector and spliced it in there and it worked.....kinda
                When the rpms drop down to 1000 or lower the tack needle sweeps over to the right side of the display, over on the 10k spot, when I give it some gas it jumps over to 2k then works as intended until I let off the throttle and it jumps over to 10k again

                From what i understand the 1600 engine has the rev limiter set at 4k rpms, I rode until the limiter engaged for a second and saw the tach was at 6k rpms
                so it looks like its reading 2k more rpms than the engine is actually at
                This kinda makes sense as far as the tach needle going to the other side, the tach display goes from 0 to a notch at 1000 then 2 then another notch etc
                If the tach thinks its moving below 1000 it has nowhere to go but backwards,
                I think if i get the right size resistor in there it could potentially get it where it should be?
                I'm not sure but either way at least it kinda works


                Comment


                • #68
                  Overkill Jones, I am reading your post and I was shocked to read about your friend. Certainly there will be prayers from me for his family and friends and for you so you may find comfort and accept that this is "His" will. I agree with you. I don't think God will use this situation to scare you from riding.
                  I will not apologize for being white, being straight or for loving this country.

                  Comment


                  • #69
                    Originally posted by highvoltage View Post
                    Overkill Jones, I am reading your post and I was shocked to read about your friend. Certainly there will be prayers from me for his family and friends and for you so you may find comfort and accept that this is "His" will. I agree with you. I don't think God will use this situation to scare you from riding.
                    Thank you high voltage, this has been disturbing to say the least but God has been giving me peace about the situation
                    Most of my family members did not want me to continue riding but at a time like this riding really gets my mind off everything for a while

                    Comment


                    • #70
                      Jesus OJ, I'm really sorry to hear about your friend. I can't imagine what that must have been like. My prayers go out to you and his family. Glad to hear you're staying positive, and you're right, God doesn't want us to live in fear. BTW, if you haven't already, time to re-torque your steering head bearings, bleed your brakes, and upgrade to a Roadwing rear shock and Progressive front fork springs. Also, if you still have either Bridgestones or Dunlops, get rid of them and replace with some better rubber. I am a FIRM believer of having a good handling bike, not only for the fun but for the safety. In my book that's more important than performance.

                      P.S. Sorry I missed this when you posted it. We're here for you bud.

                      Comment


                      • #71
                        Terrible time for you. So sorry for your loss of your friend and riding buddy. Prayers sent to you and your close friends from me and my family. Take care of each other. JC

                        Comment


                        • #72
                          Thanks for the prayers everyone, day by day it is getting better.

                          Comment


                          • #73
                            Originally posted by Doc_V View Post
                            Jesus OJ, I'm really sorry to hear about your friend. I can't imagine what that must have been like. My prayers go out to you and his family. Glad to hear you're staying positive, and you're right, God doesn't want us to live in fear. BTW, if you haven't already, time to re-torque your steering head bearings, bleed your brakes, and upgrade to a Roadwing rear shock and Progressive front fork springs. Also, if you still have either Bridgestones or Dunlops, get rid of them and replace with some better rubber. I am a FIRM believer of having a good handling bike, not only for the fun but for the safety. In my book that's more important than performance.

                            P.S. Sorry I missed this when you posted it. We're here for you bud.
                            Thanks Doc, overall God has changed my outlook on life since this all happened, He gives and takes away and I know it was His will that brought my friend to heaven that day.
                            I don't know if they have motorcycles in heaven but if they do I'm sure he's got a sweet chopper now.


                            Since this all happened my motivation to work on the bike has come to a crawl, I've also been spending more time serving others before serving my own needs so progress is on thee backburner at the moment.

                            I did manage to dial in the speedometer finally, it looks like I had the pickup for it a little too close to the magnets mounted on the rear rotor, I adjusted it out a bit and it works now, just a few mph off but it works.

                            The seat came out alright, I kinda biffed it when planning so a few things are off but it was a good learning experience for next time

                            I am currently working on crash bars for the bike, I plan on mounting them to the 4 front engine mount bolts on the downtubes
                            I will be using just some 1" tube for the crash bar itself, I figure I can get some matching metal flake grips to put on there
                            Pictures coming soon!

                            Comment


                            • #74
                              So I managed to get most of the crash bar/highway bar done
                              I used some 5/16" diamond plate for the mounting plates and a 1" tube for the bar itself
                              I now realize why most crash bars have the delrin ends on them, while scooting towards it on my stool to tack the tube in place I managed to slam my kneecap into it leaving a nice slice on there

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                              I managed to find some old metal flake grips to mount on the ends
                              I utilized the 4 engine support bolts near the front of the frame to mount the plates I made

                              I will be ordering some replacement delrin sliders online, I plan on remaking it with heavier duty plate and a bigger tube

                              I also grabbed these bars at the long beach motorcycle swap meet for only $15

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                              • #75
                                Click image for larger version

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                                Here is a picture of the seat I was working on
                                While making it I learned quite a bit
                                I didn't realize where the seat would crease (passenger and driver seat contour)
                                The foam I used for the pleats was too thin
                                I also came to realize punching through several layers of vinyl takes a strong sewing machine

                                Overall it looks decent for the time being, when I manage to scrape together some money I plan on getting a sailrite sewing machine for future seats

                                Comment


                                • #76
                                  For now the roadstar will take a much needed break from being worked on
                                  I have a honda shadow I just picked up that I managed to pull the engine from, I will be rebuilding it since there was a small knock in the engine, seems like it can be saved
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                                  This is my 3rd shadow ace 750, I plan on making it into my off road bike

                                  I also have a 79 xs650 that has been collecting cobwebs in the garage, I plan on making it into a rigid frame bondo chopper
                                  The plan is to paint it purple, black, and silver with a bride of frankenstein shifter knob that I will sand cast (gotta learn how to do that )
                                  It will be the mating bike for the roadstar and will be titled "The Bride"

                                  My friend that recently passed away had a suzuki savage 650, his parents told me they would like me to have the bike so I plan on making a tribute chopper with it that he would have enjoyed

                                  My plate is far beyond full, looks like I will have a few projects to work on for years to come

                                  The xs650 is next, I have a donor engine with more spare parts than I can handle, my goal is to get it done by born free 12 in june of 2020
                                  Then the Shadow 750, it will be a park ranger themed bike for born free 13 in 2021
                                  After that the savage chopper will come into play for born free 14 in 2022

                                  Comment


                                  • #77
                                    Read your post Ok Jones and my condolences for your loss. In some cases wives and or girlfriends, come and go but your close homeboys are with you forever, even when they've gone to Rider's Heaven. I'm 61 years old now and I still have my buddies that I've known since Kindergarten. Take care, ride on. Jesse from East L.A.

                                    Comment


                                    • #78
                                      Originally posted by jcova58 View Post
                                      Read your post Ok Jones and my condolences for your loss. In some cases wives and or girlfriends, come and go but your close homeboys are with you forever, even when they've gone to Rider's Heaven. I'm 61 years old now and I still have my buddies that I've known since Kindergarten. Take care, ride on. Jesse from East L.A.
                                      Thank you jcova, I'm sure he's doing wheelies up waiting for the rest of us

                                      Comment


                                      • #79
                                        So I ended up finding a goldwing shock for $185 shipped
                                        I just need to locate a rap and I should be all set

                                        Comment


                                        • #80
                                          So I ended up getting a RAP( remote adjustable preload) from a suzuki burgman an400
                                          Only cost me about $30 shipped
                                          It took a while but I finally figure out how to fill and bleed the darn thing
                                          Fought it and cussed until I was covered in suspension oil (i used ss7 5w oil) until i decided to pray about it, 5 minutes later I screamed in joy as God gave me the wisdom to figure it out
                                          I ended up taking off the top cap, then removing the plate under it using some needle nose pliers, then more prayer as I tried to remove the piston, yet again the big man upstairs helped me out and I pulled the piston out by prying the needle nose pliers against the inside walls of the piston
                                          It popped out and let out another triumphant scream
                                          I was able to finally fill the reservoir, it took quite a bit of oil, much more than my first attempts, there is no sort of return spring in there so I guess that's the only way to do it
                                          I hooked it up to the line attached to the shock, pumped the rap down, loosened the banjo bolts a few times on the rap and shock body to bleed it and BAM it was working like a charm
                                          I managed to pop out the stock bushing from the shock and now I'm just playing the waiting game until I get the last few parts I need from mcmaster carr
                                          I had to order some flanged sleeve bearings and shims, of course the shims only come in a pack of 24 and I only need 2 so if anyone needs some let me know before they sit in my garage until the end of time gathering dust

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